Folding box

ABSTRACT

A box, foldable from a flat blank into a three-dimensional construction, which does not require an attachment of confronting walls, as by gluing, stapling or the like, as is characteristic of seamed boxes. Instead, the body of the box includes overlapping top walls which are either wrapped about erect or standing side walls and held in place by cooperating locking means on the side and top walls or otherwise held in overlapping relation. In either case, a definitive interior space or compartment is defined by the body having said overlapping walls.

United States Patent Ross [54] FOLDING BOX [72] Inventor: Donald R. Ross, 126 California Avenue, Freeport, NY. 11520 [22] Filed: March 23, 1971 211 App]. No.2 127,273

[52] US. Cl. ..229/39 R, 206/45.31 [51] Int. Cl. ..B65d 5/10 [58] Field of Search ..229/39, 38, 41 C, 45; 206/4531 [56] References Cited UNITED STATES PATENTS 1,996,997 4/1935 Inman ..229/39 1,568,982 1/1926 Lengsfield ..206/45.31 1,860,586 5/1932 Mcllhenney ..206/45.31 2,060,513 11/1936 Marx ..229/38 X 2,297,100 9/1942 Ely ..229/39 R X 2,553,157 5/1951 Worfford ..229/39 R X 2,611,529 9/1952 Currivan ..229/38 [451 Nov. 21, 1972 2,681,174 6/1954 Bergstein ..229/38 2,749,016 6/1956 Cote ..229/39 R 2,954,152 9/1960 Buttery et a1. ..229/39 R 3,451,535 6/1969 Caplan ..229/39 R X Primary Examiner-Davis T. Moorhead Att0mey-Bauer & Amer [57] ABSTRACT A box, foldable from a flat blank into a three-dimensional construction, which does not require an attachment of confronting walls, as by gluing, stapling or the like, as is characteristic of seamed boxes. Instead, the body of the box includes overlapping top walls which are either wrapped about erect or standing side walls and held in place by cooperating locking means on the side and top walls or otherwise held in overlapping relation. In either case, a definitive interior space or compartment is defined by the body having said overlapping walls.

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FOLDING BOX The present invention relates generally to folding boxes, and more particularly to an improved folding box in which the gluing attachment or other means of connecting confronting walls of the same to contribute to its box construction is eliminated. Instead, the box shape is achieved using an overlap in the walls and cooperating locking means to retain this overlap.

In the present practice of designing a folding box, there is great emphasis placed on conserving construction materials for the box, such as cardboard or the like, and thus producing the box with a minimum number of walls or flaps. Boxes using minimum materials of construction, however, require gluing or a similar connection of confronting walls along at least one seam in order to provide the required box shape or construction. This gluing or similar operation, in turn, neces sitates the use of machinery and increased handling, and for all practical purposes offsets the savings which were afforded by the use of minimum construction materials.

Broadly, it is an object of the present invention to provide an improved folding box overcoming the foregoing and other shortcomings of the prior art. Specifically, it is an object to provide a folding box which is readily transformed by the customer from a flat blank into a rigid construction merely by folding, and without any prior gluing or other attachment of walls or flaps of the blank, as along a seam.

A folding box embodiment demonstrating objects and advantages of the present invention includes a body, delineated into walls providing a box-like enclosure, which, in practice, is readily wrapped about erect or standing side walls and held in said wrapped condition. By including walls at the opposite terminal ends of the body which overlap each other when' wrapped about said end walls, and also providing cooperating locking means on said end said overlapping walls, the box shape or construction is retained without the need for prior gluing or otherwise partially completing the box construction before a shipment of the same to the user.

In another embodiment, advantageous use is made of the inner of the two overlapping walls, wherein the same is operatively associated with structure which suspends into the box compartment to either serve as a divider, to fill an unused void, or other such noteworthy purpose.

The above brief description, as well as further objects, features and advantages of the present invention, will be more fully appreciated by reference to the following detailed description of presently preferred, but nonetheless illustrative embodiments in accordance with the present invention, when taken in conjunction with the accompanying drawings, wherein:

FIGS. l-3 illustrate a first embodiment of the invention, namely to wit:

FIG. 1 is a plan view of a blank foldable into a first embodiment of an erect box according to the present invention;

FIG. 2 is a perspective view, on an enlarged scale, of one end of the box in a partially completed erect condition; and

FIG. 3 is similarly a perspective view of an end of said box, but after the completion of the erection thereof, and illustrates further details of the cooperating locking means for maintaining said erect condition of said box;

FIG. 4 is a perspective view of a second embodiment of a folding box according to the present invention, said box having a display window therein, and wherein the movement of a display window panel into its operative position is illustrated in phantom line and full line perspective;

FIGS. 5 and 6 are related to additional embodiments of a folding box according to the present invention, each of said figures being perspective views of one end of said boxes and illustrate the range of shapes that can be embodied by said boxes;

FIGS. 7-12 illustrate further embodiments. which make advantageous use of the overlapping walls which characterize the box construction hereof, namely, to wit:

FIG. 7, like FIG. 1, is a plan view of a blank which folds into said box embodiment;

FIG. 8a is an end view illustrating the folding of said blank into a box which is more particularly illustrated, also in end view, in FIG. 8b;

FIG. 9 is an elevational view, in section taken on line 99 of FIG. 8a, showing further structural details;

FIGS. 10, 11 and 12 illustrate still another embodiment, FIG. 10 being a perspective end view of said embodiment having a void-filling structure, illustrated in phantom perspective, operatively associated with it;

FIG. 11 is a plan view of the void-filling structure; and

FIG. 12 is an elevational view, in section taken on lines 12-12 of FIG. 10, illustrating further structural details.

Reference is now made to the drawings, and in particular to FIGS. 1-3 illustrating a first embodiment of a folding box demonstrating objects and advantages of the present invention. The box, illustrated in FIG. 3 in its erect condition and generally designated 10, will be understood to be foldable into said erect condition, in a manner which will subsequently be described in detail, from a flat blank, illustrated in FIG. 1 and generally designated 12 therein. That is, blank 12 is adapted to be erected into box 10 as a result of the folding thereof, and then is maintained in said erect condition by cooperating male and female locking members respectively generally designated 14 and 16. Thus, as distinguished from so-called seamed boxes wherein confronting sections of walls forming said boxes are adhesively secured to each other, stapled or otherwise connected or attached to each other, the box 10 hereof is maintained in its erect FIG. 3 condition solely as a result of the locking function of the cooperating locking means 14 and 16.

Blank 12 will be understood to be constructed of cardboard or other suitable material, and as clearly illustrated in FIG. 1, has lines of perforations 18-21 delineating a section in its medial portion which serves as a bottom wall 22 of the erected box 10. A pair of end walls 24 and 26 are contiguous to opposite ends of the bottom wall 22, these end walls respectively starting from the lines of perforations 18 and 20.

A pair of side walls for the erected box 10, designated 28 and 30 in FIG. 1, are contiguous to the opposite sides of the bottom wall 22. It should be noted that the side walls 28 and 30 are of a greater longitudinal extent than the bottom wall 22 and that therefore in order to permit the end walls 24 and 26 to fold along the perforation lines 18 and 20, the end walls 24 and 26, during die cutting of the blank 12, are physically separated from each other, as at 32, in order to permit the end walls 24 and 26 to fold along the lines 18 and 20.

Completing the blank 12 are a pair of top walls 34 and 36 delineated at opposite ends of the blank 12 by vertically oriented lines of perforations 38 and 40. It will, of course, be understood that in lieu of perforated lines, such as lines 18-21 and 30 and 40, that use can be made of conventional line impressions made into the body of the blank 12 and which serve, in a well understood manner, as fold lines along which the various walls of the box readily fold relative to each other during erection of the blank into a three-dimensional box 10.

Each of the top walls 34 and 36 are provided, at opposite ends, with die cut hold-down slits 42 and 44, the significance of which will soon be apparent.

Referring now specifically to the previously noted cooperating locking means 14 and 16, the male locking member 14 thereof, as perhaps is best illustrated in enlarged FIG. 2, includes a locking tab 46 of generally rectangular shape. Specifically, the opposite converging sides 48 thereof each cooperate to subtend an acute angle 49 with end supporting sections 50 and 2, which are coincident with the upper or free edges of each of the end walls 24 and 26.

The female locking means 16 is formed as an end notch in each of the opposite ends of the top walls 34 and 36, each such notch being bounded by opposing curved edges 54 and 56 and an inwardly disposed straight edge 58. It will be understood that the transverse extent of each notch 16 that is bounded by the edge 58 is generally equal to the size of each tab 46 at its connection, as at 60, along the top edge of each of the side walls. This, in practice, provides each of the tabs 46 with a force or friction fit in a cooperating locking notch 16. 'It will be further understood that the clearance 49 adjacent each of the tabs 46 is sufficient to accommodate the bulk which is presented by the double thickness of the superposed or overlapping top walls 34 and 36.

In respect to the foregoing, it will be understood that the following is the recommended procedure for folding blank 12 into a box 10. First, the end walls 24 and 26 are folded out of the plane of the bottom wall 22 along the lines 18 and 20. Next, the box is generally formed about the end walls 24 and 26 by the remainder of the blank being wrapped about the standing end walls 24, 26. Specifically, each of the side walls 28 and 30 are next folded against the sides of the end walls 24 and 26 along the lines 19 and 21. Then, the top walls 34 and 36 are folded along the lines 38 and 40, these walls being folded into overlapping relation with each other, as shown in FIGS. 2 and 3. Thus, in the operative position of each end wall, as exemplified by end wall 24 in FIGS. 2 and 3, the same is positioned so that the upper edge sections 50 and 52 are located beneath and in supporting relation to the overlapping top walls 34 and 36, and the male locking tab 46 thereof is projected in locking or holding relation through a cooperating female locking notch 16. Specifically, as is perhaps best illustrated in FIG. 3, the inwardly projecting curved edges 54 and 56 are advantageously in holding relation to the rear of each tab 46 while the outwardly diverging edges 48 thereof are in holding relation projected to the outside of the overlapping top walls 34 and 36.

As further illustrated in FIG. 3, it is contemplated that each tab 46 be advantageously held in a flush position against the top wall 34, and this is preferably achieved by inserting a hold-down tongue 62 formed along the base of each tab 46 into a cooperating slit 44.

Reference is now made to a second embodiment-of a box 64 made according to the present invention and illustrated in FIG. 4. Box 64 will be understood to embody essentially the same structural features already described which, for brevitys sake, will not again be described. Instead, the description will be confined only to additional features embodied by box 64 not previously described. In this connection, box 64 in.- cludes overlapping top walls 66 and 68 which are each die cut or otherwise appropriately provided with display window openings 70 and 72 which in the overlapping operative position of the top walls 66 and 68 align with each other. A transparent or translucent display panel 74 is then advantageously placed in an interposed position between the overlapping top walls 66 and 68 in a display position relative to the windows 70 and 72.

Additional embodiments respectively designated 76 and 78 in FIGS. 5 and 6 will also be understood to be substantially similar to box embodiment 10 of FIGS. 1-3 and are illustrated herein to demonstrate the range of shapes that are possible in accordance with the present invention. Specifically, box 76 is of a truncated rectangular shape in cross section and is achieved by adding side sections 80 and 82 to each end wall 84.

Similarly, the shape of box 78 of FIG. 6 also requires flap additions 86 and 88 to each end wall 90, and also an increased size and an additional fold line 92 in each of the opposite side walls 94 and 96. From the foregoing, it should be readily appreciated that there has been described herein a noteworthy folding box, as exemplified by the embodiments 10, 64, 76 and 78, which each are readily foldable from flat blanks into threedimensional constructions and are each maintained in said constructed or erect condition by cooperating locking means, and specifically without the need for gluing, stapling or otherwise connecting any of the walls of the boxes.

Reference is now made to the folding box embodiments of FIGS. 742 inwhich advantageous use is made of the overlapping relationship of at least two of the walls which bound the box enclosure. Also in these embodiments, more conventional cooperating locking means are utilized to retain the overlapping relationship rather than the interfitting cooperating male and female locking members 14 and 16 of the previously described embodiments. The use of these conventional locking means is possible because the contents of the box itself contributes to maintaining the inner of the overlapping walls in place about the box enclosure. Also, this inner wall is operatively associated with voidfilling structure which occupies a depending position into the box enclosure and which also contributes to holding this wall in place about the box enclosure.

A first form of this folding box embodiment is illustrated in FIGS. 7, 8a and 8b. Specifically, the final erect condition of the box is illustrated and generally designated 100 in FIG. 8b. In FIG. 7, the blank from which box 100 is made is generally designated 102. FIG. 8a illustrates how the blank 102 is folded into the box 100.

Blank 102 is delineated by lines of perforations, individually and collectively designated 104, into various walls which cooperate to bound an interior enclosure or compartment in the erect condition of box 100.

Specifically, in a central location, the perforations 104 delineate a generally rectangular bottom wall 106 having opposite end flaps 108 and 110 which each have a tab projection 112 and 114 formed thereon. Adjacent the bottom wall 106 are side walls 116 and 118. Then, just like the prior described embodiment of FIGS. 1-6, the blank 102 hereof includes top walls 120 and 122 which, in the erect condition of the box 100, have an overlapping relation which when maintained provides the box-like shape of the blank 102. Each of the top walls 120 and 122 and each of the side walls 116 and 118 also have flaps forming a continuous part thereof which, in the erect condition of the box 100, cooperate with each of the end flaps 108 and 110 to form end closure structure for the box 100. These flaps on the top wall 122 are designated 124 and 126. At this point, it is also convenient to note that on the lines of demarcation between the flaps 124, 126 and top wall 122, there are notches 128 and 130 which are of a size to accommodate the previously noted locking tabs 1 l2 and 114.

Each of the side walls 116 and 1 18 have end flaps, individually and collectively designated 132.

Top wall 120, like top wall 122, also has end flaps; but, as clearly illustrated in FIG. 7, these consist of two spaced apart end flaps 134 and 136 at one end, and 138 and 140 at the other end. As will be better understood subsequently, the space between these flaps allows the unimpeded projection of the locking tabs 112 and 114 through their cooperating notches 128 and 130, respectively.

Completing the construction of the blank 102 is an integral void-filling flap, generally designated 142, consisting of the two panels 144 and 146 delineated from each other by the line of perforations 148. The entire flap 142 is free of attachment from the wall 120 along its opposite edges 150 and 152 but is connected to this wall along the line of perforations 154.

In the folding of the blank 102 into the box 100, normal procedures are followed to provide the partially completed box illustrated in FIG. 8a. In this partially folded condition, wall 120 assumes the innermost position of the overlapping relation and thus is in facing relation to the bottom wall 106. Ordinarily, the contents of the box would have been placed in position on the bottom wall 106; however, these contents for present purposes have been omitted so as not to obscure the structural features of the box 100. In any event, it may be assumed that these contents do not entirely fill the enclosure of the box and that there is a void in the central portion which must be occupied, otherwise there will be shifting of these contents. In such situations, it is common to employ a so-called rat trap". Instead, and in accordance with the present invention, advantageous use is made of the void-filling flap 142 to perform the function of a rat trap". Specifically, flap 142 is folded so that the panel 146 is vertically oriented and the lower panel 144 arranged transversely thereof and in a position resting upon the bottom wall 106. It should be readily appreciated that the vertically oriented edges 154 and 156 of the panel 146 effectively serve as obstacles minimizing shifting movement of the contents within the box enclosure.

Box 100, as depicted in FIG. 8b, is then achieved by merely folding the wall 122 through closing movement upon the wall 120. Following this, both ends of the box are closed. For example, flaps 132, 138 and are tucked in, and the end flap 126 folded in holding position over these flaps. This also advantageously locates the notch 128 in relation to the locking tab 112 permitting the projection of this tab into this notch, all as is clearly illustrated in FIG. 8b. In this manner, outer wall 122 is held in its overlapping relation to the inner wall 120.

Another form of the foregoing embodiment of box 100 is illustrated in the remaining FIGS. 10-12. For brevitys sake, similar structural features will not again be described. The significant difference in this form of box is that the integral void-filling flap 142 is replaced by a separate void-filling structure 158 shown in isolated plan view in FIG. 11. Structure 158 is formed by four panels 160, 162, 164 and 166, all but the middle panel having attaching tabs 168 thereon.

As is clearly illustrated in FIGS. 10 and 12, the inner top wall 170 of the erect box 172 has strategically located notches 174 therein so that the tabs 168 can be projected through these notches and accordingly connected to the wall 170. The tabs 168 are then advantageously folded flat against the wall 170 and their presence is then effectively masked by the overlying outer wall 176. As in previously described embodiments cooperating connecting means, such as a tab 178 on an end wall 180, is utilized to hold the walls 170 and 176 in their overlapping relation.

Although the integral flap 142 and the added flap or structure 158 were described herein as being useful as void-filling structures, it will be understood that they can just as easily be utilized for other functions, such as subdividing the box enclosure or compartment or some similar function. For example, returning again to the embodiment as depicted in FIG. 8a, it should be readily appreciated that inner wall 120 can be die cut in such a manner that a portion of it is readily detachable and can therefore function as a pop-up or stand-up advertising piece. In a conventional box, which has only one wall, weakening such wall with perforations to provide a stand-up advertising piece could not be tolerated, but this is not a shortcoming with the present invention, since the outer wall 122 readily provides the necessary structural stability to the box. In addition, the outer wall 122 effectively masks any perforations which are provided in the inner wall 120 whether for a stand-up advertising piece or for a void-filling structure which is suspended into the box interior.

A latitude of modification, change and substitution is intended in the foregoing disclosure, and in some instances some features of the invention will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the spirit and scope of the invention herein.

What is claimed is:

l. A box having an erect condition defining an enclosure and foldable along fold lines into said erect condition from a flat blank, said flat blank comprising a substantially planar body having fold lines delineating a bottom wall for said box having opposite side edges and end edges, side walls adjacent each said side edge of said bottom wall, a pair of top walls, each contiguous to one side wall, a pair of end walls, each contiguous to each said end edge of said bottom wall, and cooperating locking means on said end wall and said top walls having a overlapping relation in said erect condition of said box and said locking means thereof comprising a pair of aligning notches located in an end edge of each of said top walls, and said locking means of said end walls comprising in each said end wall a supporting edge coincident with each said free edge thereof and having a locking tab centrally located along said support edge, each said end wall in said erect condition of said box having an operative position in which said supporting edge thereof is in supporting relation beneath said overlapping top walls and said locking tab is projected in holding relation through said aligned notches,

whereby said erect condition of said box is maintained solely by said operative positions of said cooperating locking means.

2. A box as defined in claim 1 wherein said overlapping walls have aligned display window openings therein, and including a display panel in an interposed position between said top walls and disposed over one said display window opening.

3. A box as defined in claim 1 wherein said top walls include slit means located inwardly adjacent said notches, and said locking tabs include hold-down tongues thereon adapted to be projected into said slit means, whereby said locking tabs are adapted to be held flush against said overlapping top walls in said erect condition of said box.

4. A box as defined in claim 3 wherein each said end wall is of the same transverse extent as said bottom wall and is equal in height to said side walls, whereby in said 

1. A box having an erect condition defining an enclosure and foldable along fold lines into said erect condition from a flat blank, said flat blank comprising a substantially planar body having fold lines delineating a bottom wall for said box having opposite side edges and end edges, side walls adjacent each said side edge of said bottom wall, a pair of top walls, each contiguous to one side wall, a pair of end walls, each contiguous to each said end edge of said bottom wall, and cooperating locking means on said end wall and said top walls having a overlapping relation in said erect condition of said box and said locking means thereof comprising a pair of aligning notches located in an end edge of each of said top walls, and said locking means of said end walls comprising in each said end wall a supporting edge coincident with each said free edge thereof and having a locking tab centrally located along said support edge, each said end wall in said erect condition of said box having an operative position in which said supporting edge thereof is in supporting relation beneath said overlapping top walls and said locking tab is projected in holding relation through said aligned notches, whereby said erect condition of said box is maintained solely by said operative positions of said cooperating locking means.
 1. A box having an erect condition defining an enclosure and foldable along fold lines into said erect condition from a flat blank, said flat blank comprising a substantially planar body having fold lines delineating a bottom wall for said box having opposite side edges and end edges, side walls adjacent each said side edge of said bottom wall, a pair of top walls, each contiguous to one side wall, a pair of end walls, each contiguous to each said end edge of said bottom wall, and cooperating locking means on said end wall and said top walls having a overlapping relation in said erect condition of said box and said locking means thereof comprising a pair of aligning notches located in an end edge of each of said top walls, and said locking means of said end walls comprising in each said end wall a supporting edge coincident with each said free edge thereof and having a locking tab centrally located along said support edge, each said end wall in said erect condition of said box having an operative position in which said supporting edge thereof is in supporting relation beneath said overlapping top walls and said locking tab is projected in holding relation through said aligned notches, whereby said erect condition of said box is maintained solely by said operative positions of said cooperating locking means.
 2. A box as defined in claim 1 wherein said overlapping walls have aligned display window openings therein, and including a display panel in an interposed position between said top walls and disposed over one said display window opening.
 3. A box as defined in claim 1 wherein said top walls include slit means located inwardly adjacent said notches, and said locking tabs include hold-down tongues thereon adapted to be projected into said slit means, whereby said locking tabs are adapted to be held flush against said overlapping top walls in said erect condition of said box. 